Techniques for making mono-axially oriented draw tape which is usable in a draw tape bag

ABSTRACT

A technique involves making mono-axially oriented draw tape. The technique involves forming a solid sheet of thermoplastic material from molten thermoplastic material, and producing a set of draw tape feeds from the solid sheet of thermoplastic material. The technique further involves stretching and annealing the set of draw tape feeds to orient molecules within the set of draw tape feeds such that tensile strength of each draw tape feed is greater in a first direction than in a second direction which is substantially perpendicular to the first direction. As a result, the draw tape feeds are extremely strong in the first direction and well-suited for use in draw tape bags.

[0001] One conventional draw tape bag uses draw tape which ismanufactured using a single-layer blown-film approach. In thesingle-layer blown-film approach, the draw tape manufacturer extrudes ablend of thermoplastic polymers into molten thermoplastic material, andforms a tube of the molten thermoplastic material. The manufacturerblows air into the tube to expand the tube in multiple directions (e.g.,to expand the tube in both the horizontal and vertical directions tobi-axially orient molecules in the tube in both directions). Themanufacturer then cuts the tube lengthwise to form one or more sheets ofthermoplastic film. Next, the manufacturer cools the sheets and windsthe sheets onto large rollers to form master rolls of thermoplasticfilm. In a secondary operation, the manufacturer unwinds thethermoplastic film from the master rolls, slits the thermoplastic filminto individual draw tapes, and winds the individual draw tapes intoindividual pads or spools for subsequent use in draw tape bags.

[0002] In the single-layer blown-film approach, the manufacturertypically uses, as the blend of thermoplastic polymers, a mixture ofhigh-density polyethylene (HDPE) and lower-density material such aslinear low-density polyethylene (LLDPE), low-density polyethylene(LDPE), or ethyl vinyl acetate (EVA) (e.g., 80% HDPE and 20% LLDPE). TheHDPE provides strength to the draw tape so that it is unlikely that theuser will overstretch or break the draw tape when pulling on the drawtape. The lower-density material lowers the melting point of the drawtape so that a draw tape bag manufacturer can reliably attach the drawtape to the thermoplastic panels of the bag in a shorter period of timethan if the manufacturer were to use a draw tape made entirely of HDPE(e.g., using a heat sealing process that requires less time and lessheat than that which would be used for a draw tape consisting entirelyof HDPE). The lower-density material also makes the draw tape softer fora more comfortable feel, i.e., more ergonomically appealing to a user'shand than draw tape made entirely from HDPE.

[0003] Another conventional draw tape bag uses multi-layer draw tapewhich is manufactured using a multi-layer blown-film extrusion approach.In the multi-layer blown-film extrusion approach, the draw tapemanufacturer extrudes different materials through a complex die havingmultiple channels and multiple openings through which the differentmaterials pass. In particular, the manufacturer (i) extrudes HDPEthrough a first channel and through a middle opening of the die, and(ii) extrudes a lower-density material such as LLDPE, LDPE, or EVAthrough a second channel and through two peripheral openings, oneperipheral opening being on each side of the middle opening, to form amulti-layered sheet having a central core of high-density polyethyleneand two outer layers of lower-density material. The manufacturer thencools the multi-layered sheet and winds the multi-layered sheet onto alarge roller. Then, in a secondary operation, the manufacture unwindsthe multi-layered sheet, slits the multi-layered sheet into individualdraw tapes, and winds the individual draw tapes onto individual pads orspools for subsequent use in draw tape bags.

[0004] As in the multi-layer blown-film approach, the use of the HDPE(as the core) in the multi-layer extrusion approach provides strength tothe draw tape so that it is unlikely that the user will overstretch orbreak the draw tape when pulling on the draw tape. The lower-densityouter layers have lower melting points than the high-densitypolyethylene thus enabling a draw tape bag manufacturer to attach thedraw tape to the thermoplastic panels of the bag in a shorter period oftime and to use less heat than if the manufacturer were to use a drawtape made using the single-layer blown-film approach with materialconsisting predominantly of HDPE.

SUMMARY OF THE INVENTION

[0005] Unfortunately, there are deficiencies to above-describedconventional approaches to manufacturing draw tape. For example, in theearlier-described conventional single-layer blown-film approach, thedraw tape is typically bi-axially oriented and thus does not achievemaximum strength in the lengthwise direction, i.e., along the length ofthe draw tape. As a result, some draw tapes made using the single-layerblown-film approach may stretch and/or break with a relatively smallamount of force (e.g., less than 20 pounds of force). Additionally, thelengths of the draw tape made using the single-layer blown-film approachare limited by the length of the master rolls and such limited lengthsplace limitations on draw tape bag manufacturers. In particular, thedraw tape manufacturer typically splices together individual draw tapesonto a single hub in order to provide a spool of draw tape longer thanthe length of a master roll. Such splices create potential points ofweakness in the draw tape (i.e., points which are prone to failure). Forinstance, the draw tape may break when a user (e.g., a consumer) pullson the draw tape in an attempt to close or lift a draw tape bag thusresulting in customer dissatisfaction. Also, the draw tape may break,stretch or snag in equipment during the draw tape bag manufacturingprocess thus resulting in costly production downtime and a waste ofmaterials. Furthermore, the blown-film process is an inefficient use ofresources since a significant amount of resources must be invested inwinding the thermoplastic film onto large rollers to form master rollsshortly after the thermoplastic film is made and then, as a secondaryprocedure, unwinding the master rolls to cut the film into individualfeeds and winding the feeds into pads or spools. In some cases, the costfor such resources (winding equipment, unwinding equipment, additionalpersonnel, etc.) makes the blown-film approach prohibitively expensive.

[0006] Additionally, in the earlier-described conventional multi-layerblown-film extrusion approach, manufacturing of the multi-layer drawtape requires (i) handling different raw materials (e.g., HDPE and EVA)and (ii) using a complex die having multiple channels and multipleopenings. Accordingly, the multi-layer draw tape resulting from themulti-layer blown-film extrusion approach can be substantially moreexpensive and more difficult to manufacture than a single-layer drawtape (e.g., draw tape made from the single-layer blown-film approach).Furthermore, a significant amount of time and heat is required to attachthe multi-layered draw tape to the thermoplastic panels of the draw tapebag. In particular, each heat seal (i.e., the attachment point betweenthe ends of two pieces of multi-layered draw tape and two folded-overthermoplastic panels forming tubular hems) requires heat to penetratethrough a layer of high-density polyethylene (the core of each drawtape) in order to melt a lower-density layer and thermoplastic materialon the opposite side of the draw tape. Such large amounts of time andheat result in an increase in cost per draw tape bag by limiting theutilization of the draw tape bag manufacturing equipment. Moreover, inthe multi-layer blown-film extrusion approach to making draw tape, as inthe single-layer blown-film approach, the draw tape is bi-axiallyoriented and thus does not achieve maximum strength in the lengthwisedirection, i.e., along the length of the draw tape. As a result, somedraw tapes made using the multi-layer blown-film approach may stretchand/or break with a relatively small amount of force (e.g., less than 20pounds of force). Additionally, in the multi-layer blown-film extrusionapproach to making draw tape, as in the single-layer blown-filmapproach, the lengths of the draw tape made using the multi-layerblown-film approach are limited by the length of the master rolls andsuch limited lengths place the same limitations (the need for splices,higher processing costs) on draw tape bag manufacturers usingmulti-layer blown-film draw tape as single-layer blown-film draw tape.

[0007] Embodiments of the invention are directed to techniques formaking mono-axially oriented draw tape. Such techniques involvestretching and annealing a feed of draw tape to orient molecules withinthe draw tape feed such that tensile strength is greater in onedirection (e.g., the lengthwise direction along the draw tape feed). Byorienting the draw tape in one direction only, this method allows themanufacturer to make substantially stronger draw tape. Moreover, themanufacturer can use a lower-density material (e.g. LLDPE) and achieveequal or greater draw tape strength than conventional manufacturersusing HPDE. The advantage of this is that lower-density materialsrequire less heat and time to fasten to thermoplastic panels whenmanufacturing a draw tape bag.

[0008] One embodiment is directed to a method of making mono-axiallyoriented draw tape. The method includes the steps of forming a solidsheet (a thermoplastic web or film ranging in thickness between 0.001and 0.010 inches) of thermoplastic material from molten thermoplasticmaterial, and producing a set of draw tape feeds from the solid sheet ofthermoplastic material. The method further includes the step ofstretching and annealing the set of draw tape feeds to orient moleculeswithin the set of draw tape feeds such that tensile strength of eachdraw tape feed is greater in a first direction than in a seconddirection which is substantially perpendicular to the first direction.As a result, the draw tape feeds are extremely strong in the firstdirection and are well-suited for use in draw tape bags.

[0009] In one arrangement, the molten thermoplastic material includesmolten LLDPE. In this arrangement, the step of forming the solid sheetof thermoplastic material includes the step of cooling the molten LLDPEin a bath in order to form, as the solid sheet of thermoplasticmaterial, a single solid layer of LLDPE. In one arrangement, the step offorming the solid sheet of thermoplastic material further includes thestep of (prior to the step of cooling) extruding the molten LLDPEthrough a die that defines an elongated opening. The use of the die toform a single solid layer of LLDPE can provide a simpler and lessexpensive process than that for the conventional multi-layer extrusionapproach which involves passing both HDPE and lower-density materialthrough separate channels and openings of a more-complex die in order togenerate a multi-layer draw tape.

[0010] In one arrangement, the step of stretching and annealing includesthe step of passing the set of draw tape feeds through a series ofrotating temperature-controlled rollers which are configured to stretchand anneal the set of draw tape feeds. The series of rotatingtemperature-controlled rollers includes, among other things, a firstroller which is configured to rotate at a first rate and have a firsttemperature, and a second roller which is configured to rotate at asecond rate that is different than the first rate and have a secondtemperature that is different than the first temperature. A combinationof varied temperatures and speeds (e.g., elevated temperature andincreased speed) results in stretching, orienting and annealing the drawtape. Such processing of the draw tape feeds strengthens the draw tapefeeds in an organized and consistent manner.

[0011] In one arrangement, the step of producing the set of draw tapefeeds includes the step of cutting the solid sheet of thermoplasticmaterial along the first direction to produce, as the set of draw tapefeeds, separate feeds of draw tape. This arrangement can then include afurther step of simultaneously winding the separate feeds of draw tapeonto respective hubs (e.g., cardboard cylinders) in order tosimultaneously form multiple rolls of draw tape. Accordingly, multiplerolls of draw tape can be created in a contiguous manner thusalleviating the need for winding sheets into master rolls and, in asecondary procedure, subsequently unwinding the sheets, cutting thesheets into individual feeds and winding and splicing the feeds intopads or spools. Moreover, this arrangement of the invention iswell-suited for making spools having extremely long draw tape lengthswith no weak points (e.g., with no splice points) since there is nowinding and unwinding sheets (i.e., there are no master rolls) whichlimit the feed lengths.

[0012] The features of the invention, as described above, may beemployed in manufacturing systems and methods for making mono-axiallyoriented draw tape, the tape itself, and various systems, products andmethods which use such tape, such as those of Film X, Inc. of Dayville,Conn.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The foregoing and other objects, features and advantages of theinvention will be apparent from the following description of particularembodiments of the invention, as illustrated in the accompanyingdrawings in which like reference characters refer to the same partsthroughout the different views. The drawings are not necessarily toscale, emphasis instead being placed upon illustrating the principles ofthe invention.

[0014]FIG. 1 is a block diagram of a draw tape manufacturing systemwhich is suitable for use by the invention.

[0015]FIG. 2 is a diagram of various materials which are used and/orprovided by the draw tape manufacturing system of FIG. 1.

[0016]FIG. 3 is a perspective view of an extruder die of the draw tapemanufacturing system of FIG. 1.

[0017]FIG. 4 is a block diagram of a portion of an orientating assemblyof the draw tape manufacturing system of FIG. 1.

[0018]FIG. 5 is a block diagram of a portion of a draw tape feed whichis input into the portion of the orientating assembly of FIG. 4.

[0019]FIG. 6 is a block diagram of the portion of the draw tape feedwhen output from the portion of the orientating assembly of FIG. 4.

[0020]FIG. 7 is a flowchart of a procedure which is performed by thedraw tape manufacturing system of FIG. 1.

[0021]FIG. 8 is a block diagram of a draw tape bag manufacturing systemwhich is suitable for use by the invention.

[0022]FIG. 9 is a flowchart of a procedure which is performed by thedraw tape bag manufacturing system of FIG. 8.

[0023]FIG. 10 is a perspective view of a draw tape bag produced by thedraw tape bag manufacturing system of FIG. 8.

DETAILED DESCRIPTION

[0024] Embodiments of the invention are directed to techniques formaking mono-axially oriented draw tape which is useful in certainapplications such as in draw tape bags. Such techniques involvestretching and annealing a feed of draw tape to orient molecules withinthe draw tape feed such that the tensile strength of the draw tape feedis greater in a particular direction (e.g., a direction along the drawtape feed). Accordingly, a manufacturer use certain materials (e.g.,LLDPE) to fabricate a draw tape which requires less heat and time tofasten to thermoplastic panels than conventional draw tapes (e.g., asingle-layer draw tape consisting of a blend of 20% LLDPE and 80%high-density polyethylene, a multi-layer draw tape having an HDPE core,etc.) when manufacturing a draw tape bag, but which still providesstrength that is equal to or greater than a conventional draw tape in aparticular direction (e.g., the direction along the draw tape feed).

[0025]FIG. 1 shows a mono-axially oriented draw tape manufacturingsystem 20 which is suitable for use by the invention. The mono-axiallyoriented draw tape manufacturing system 20 is capable of simultaneouslymaking multiple rolls 22 of mono-axially oriented draw tape. Each roll22 includes an inner hub 24 (e.g., a cardboard tube, cylinder, etc.) anda length of draw tape 26.

[0026] As shown in FIG. 1, the mono-axially oriented draw tapemanufacturing system 20 includes a drying/mixing assembly 28, anextruder 30, an extruding die 32, a cooling assembly 34 (e.g., a bath),a cutting assembly 36, an orientating assembly 38 (e.g., a holding unit,a heating unit, a stretching unit, and annealing unit), and a windingassembly 40. The drying/mixing assembly 28, the extruder 30, theextruding die 32 and the cooling assembly 34 form a front-end assembly42 of the system 20.

[0027]FIG. 2 shows various materials which are used and/or provided bythe mono-axially oriented draw tape manufacturing system 20. As shown inboth FIGS. 1 and 2, thermoplastic material 44 is a raw material which isuse by the system 20. In one arrangement, the thermoplastic material 44is LLDPE in a pelletized form.

[0028] The drying/mixing assembly 28 provides thermoplastic material 44to the extruder 30 which further mixes the thermoplastic material 44.Moreover, the extruder 30 grinds and sheers the thermoplastic material44 into the molten thermoplastic material 46, and pushes the moltenthermoplastic material 46 through the extruding die 32 to form a moltensheet 50 (i.e., a liquid sheet) of thermoplastic material (see FIG. 1).To this end, a rotating screw of the extruder 30 generates friction andheat to melt the thermoplastic material 44 into the molten sheet 50 ofthermoplastic material 46. It should be understood that the term sheetgenerally refers to a thermoplastic sheet, web, or film having athickness between 0.001 and 0.010 inches.

[0029]FIG. 3 shows a perspective view of a die 60 which is suitable foruse as the extruding die 32. The die 60 includes a pair of side members62 (i.e., a first side member 62-A and a second side member 62-B.) whichfasten together to define an elongated opening 64. In one arrangement,the opening 64 has a length 66 and a width 68, with the length 66 beingsubstantially greater than the width 68 in order to form the moltensheet 50. In one arrangement, the die 60 is located such that theelongated opening 64 points in a downward direction 70 such that themolten sheet 50 of thermoplastic material drops (e.g., due to gravity)into a liquid cooling bath of the cooling assembly 34 (FIG. 1).

[0030] The cooling assembly 34 cools the molten sheet 50 ofthermoplastic material into a solid sheet 52 of thermoplastic material(also see FIG. 2). In one arrangement, the cooling assembly 34 includesa tank that holds the liquid cooling bath which receives the moltensheet 50 of thermoplastic material. When the molten sheet 50 travelsthrough the cooling bath, the molten sheet 50 solidifies as itstemperature drops. As the solid sheet 52 of thermoplastic material exitsthe liquid cooling bath of the cooling assembly 34, vacuum rollers ofthe cooling assembly 34 remove excess bath liquid from the solid sheet52.

[0031] In an alternative arrangement, the cooling assembly 34 includes aset of chilled rollers (i.e., one or more chilled rollers) in place ofthe liquid cooling bath. In this arrangement, the molten sheet 50 ofthermoplastic material is extruded onto and/or through the set ofchilled rollers which cools and solidifies the molten sheet 50 (i.e.,the molten sheet 50 solidifies into the hardened sheet 52 as itstemperature drops).

[0032] Next, the cutting assembly 36 cuts the solid sheet 52 intomultiple parallel feeds 54. In one arrangement, the cutting assembly 36includes a row of blades mounted in fixed positions so that theresulting feeds 54 have defined (e.g., uniform) widths. An example rangeof widths for each feed 54 is between 0.125 to 2.000 inches. In anotherarrangement, the cutting assembly 36 includes a row of sheer bladeswhich cut the solid sheet 52 into the multiple parallel feeds 54.

[0033] The orientating assembly 38 then brings the multiple parallelfeeds 54 of draw tape into a finished state. In particular, theorientating assembly 38 stretches and anneals the multiple parallelfeeds 54 to orient molecules within the feeds 54 such that the tensilestrength of each feed 54 is greater in the lengthwise direction alongthe feed 54 than in the widthwise direction across the feed 54, thewidthwise direction being substantially perpendicular to the lengthwisedirection.

[0034]FIG. 4 shows a cross-sectional side view of suitable componentsfor the orienting assembly 38 (also see FIG. 1). The orientatingassembly 38 includes a holding unit 80, a heating unit 82 and astretching and orientating unit 84. The holding unit 80 includes a setof rotating rollers which holds the multiple parallel feeds 54 of drawtape and allows the feeds 54 to pass through at a predetermined rate.The heating unit 82 (e.g., an oven, a set of heated rollers, etc.)raises the temperature of the multiple feeds 54 of draw tape. Next,rollers 86 of the stretching and annealing unit 84 draw the multipleparallel feeds 54 of draw tape. Some of the rollers 86 (e.g., rollers86-A, 86-B, 80-C) rotate at a predetermined rate that is faster than therate of the rollers of the holding unit 80. The combination of elevatedtemperatures and increased speed results in stretching the multipleparallel feeds 54 of draw tape in the lengthwise direction (i.e. thedirection of movement of the feeds). This stretching orients themolecules in the lengthwise direction and maximizes the tensile strengthof the draw tape in the lengthwise direction. This stretching andorienting also brings the multiple parallel feeds of draw tape 54 to adesired width and thickness (e.g. 0.0015, 0.00175, 0.002, 0.003 inches)and tensile strength (e.g. 26, 28, 30 pounds). The multiple parallelfeeds 54 of draw tape next pass over other rollers which anneal thefeeds of draw tape (e.g., rollers 80-D, 80-E). The annealing rollers usevarious speeds and temperatures to permanently set the orientation ofthe multiple parallel feeds of draw tape 54. The orienting assembly 38strengthens the draw tape feeds 54 in an organized and consistentmanner, and the resulting oriented and annealed draw tape feeds 56exiting the orienting assembly 38 are well-suited for certainapplications such as handles for draw tape bags.

[0035] It should be understood that circuitry within the orientatingassembly 38 (e.g., a computer, sensors, cooling and/or heating elements,motors, etc.) operate so that the series of components provide theproper predetermined rotational speeds and temperatures. Accordingly,the feeds 54 are subjected to a consistent and uniform molecularorientating process. In one arrangement, the feeds 52 entering theorientating assembly 38 are feeds of single-layer LLDPE, and the feeds54 exiting the orientating assembly 38 are feeds of orientedsingle-layer LLDPE.

[0036]FIG. 5 is a top view of a portion of a draw tape feed 54 justprior to entering the orientating assembly 38. As shown by thearbitrarily oriented arrows 90, the molecules of the draw tape feed 54have not been substantially oriented to provide strength in anyparticular direction. Rather, the molecules of the draw tape feed 54 arerandomly oriented and thus providing fairly uniform tensile strength inall directions. That is, the molecules do not provide maximum strengthin the lengthwise direction.

[0037]FIG. 6 is a top view of a portion of a draw tape feed 56 as itexits the orientating assembly 38. As shown by the oriented arrows 92,the molecules are no long randomly oriented. Rather, the molecules arenow oriented to provide substantially greater tensile strength in thelengthwise direction 94, i.e., the direction of movement of the drawtape feed 56 through the system 20. As shown in FIG. 6, the lengthwisedirection 94 is substantially perpendicular to the widthwise direction96 across the draw tape feed 56. In one arrangement, the draw tape feed56 is thinner than the draw tape feed 54 and is stretched approximately2.8 times the length of the draw tape feed 54 (i.e., the draw tape feed56 is longer than the draw tape feed 54 by a 2.8 to 1.0 ratio).

[0038] Next, the winding assembly 40 (see FIG. 1) winds the multiplefeeds 56 exiting the orientating assembly 38 onto hubs 24 to formmultiple rolls 22 of mono-axially oriented draw tape. The feeds 56extend in a side-by-side manner from the orientating assembly 38 to thewinding assembly 40. In one arrangement, each feed 56 passes through aseries of eyelets which guide the feeds 56 onto a respective winder ofthe winding assembly 40 and a respective hub 24. In one arrangement, thefeeds 56 of draw tape roll onto hubs 24 which are substantially widerthan the feeds 56 so that the feeds 56 can traverse wind onto the hubs24 in a side-by-side manner to form, as the multiple rolls 22, spools ofmono-axially oriented draw tape 24, i.e., like spools of thread (seeFIGS. 1 and 2). In another arrangement, the feeds 56 wind onto the hubs24 in a continuous overlapping manner to form, as the multiple rolls 22,a set of pads or “pancakes” of mono-axially oriented draw tape 22, i.e.,like roles of masking tape.

[0039] It should be understood that the use of the winding assembly 40in the draw tape manufacturing system 20 enables multiple rolls 22 ofdraw tape to be created in a contiguous manner. Accordingly, there is noneed for winding sheets into master rolls and, in a secondary procedure,subsequently unwinding the sheets, cutting the sheets into individualfeeds and winding and splicing the feeds into pads or spools, as in theabove-described conventional blown-film and multi-layer blown-filmextrusion approaches. Moreover, the use of the winding assembly 40 inthe system 20 is well-suited for making spools 22 having extremely longdraw tape lengths with no weak points (e.g., with no splice points)since there is no winding and unwinding sheets (i.e., there are nomaster rolls) which limit the feed lengths. For example, each roll 22 ofdraw tape (see FIG. 1) can easily exceed 2,500 feet in length (e.g.,50,000 foot lengths, 100,000 foot lengths, etc.).

[0040] In one arrangement, the use of the die 60 of FIG. 3 in thefront-end assembly 42 (also see the extruding die 32 of FIG. 1) enablesthe draw tape to consist of a single solid layer of LLDPE. Accordingly,the system 20 can provide a simpler and less expensive draw tapemanufacturing process than that used in the earlier-describedconventional multi-layer blown-film extrusion approach which involvespassing both HDPE and lower-density material through separate channelsand openings of a more-complex die in order to generate a multi-layerdraw tape. Further details of the invention will now be provided withreference to FIG. 7.

[0041]FIG. 7 shows a procedure 100 which is performed by themono-axially oriented draw tape manufacturing system 20. In step 102,the front-end assembly 42 (FIG. 1) forms the solid sheet 52 (FIG. 2) ofthermoplastic material from molten thermoplastic material 50. In onearrangement, the front-end assembly 42 receives, as the thermoplasticmaterial 44, LLDPE in a pellet form. The extruder 30 extrudes thethermoplastic material through the extruding die 32 which defines anelongated opening, e.g., a flat or straight-shaped aperture (also seethe die 60 in FIG. 3), to form a molten sheet 50 of thermoplasticmaterial. The cooling assembly 34 cools the molten sheet 50 (e.g.,LLDPE) in a bath to form a solid sheet 52 consisting of a single-layerof thermoplastic material.

[0042] In step 104, the cutting assembly 36 produces a set of draw tapefeeds 54 from the solid sheet 52 of thermoplastic material. Inparticular, the cutting assembly 36 cuts the solid sheet 52 along thelengthwise direction (i.e., the direction of movement of the solid sheet52) to produce separate feeds 54 of draw tape.

[0043] In step 106, the orientating assembly 38 stretches and annealsthe set of draw tape feeds 54 to orient molecules within the set of drawtape feeds 54 such that the tensile strength of each draw tape feed 54is greater in the lengthwise direction than in the widthwise directionwhich is substantially perpendicular to the lengthwise direction. Inparticular, the set of draw tape feeds 54 pass through a rotatingholding unit 80-A (see FIG. 4), a heating unit 80-B that raises thetemperature of the feeds 54, and a stretching unit 80-C that rotatesfaster than the holding unit. The combination of elevated temperaturesand faster speeds stretches and orients the feeds 54. The feeds nextpass over a set of annealing rollers 80-D that use various speeds andtemperatures to permanently set the orientation of the draw tape feeds54.

[0044] In step 108, the winding assembly 40 simultaneously winds thefeeds 56 of draw tape exiting the orientating assembly 38 ontorespective hubs 22 in order to simultaneously form multiple rolls 22 ofdraw tape (also see FIGS. 1 and 2). In one arrangement, each roll 22 ofdraw tape includes a feed of single-layer mono-axially oriented LLDPE.It should be understood that even with the use of LLDPE, the draw tapecan be manufactured to have equal or greater tensile strength in aparticular direction (e.g., the lengthwise direction along the draw tapefeed) than conventional draw tape that includes HDPE (e.g., a bi-axiallyoriented draw tape made from a 20/80 blend of LLDPE and HDPE). As aresult, the draw tape feeds are extremely strong in the particulardirection and are well-suited for use in draw tape bags.

[0045] Furthermore, it should be understood that steps 100 through 108can be performed in a continuous manner as a set of ongoing steps sothat each feed 56 is essentially unlimited in length. That is, as longas the system 20 continues operating, there is no limit to the length ofeach feed 56 of mono-axially oriented draw tape. As a result, extremelylong lengths of draw tape can be produced, and such lengths can beprovided to draw tape bag manufacturers enabling the draw tape bagmanufacturers to continuously operate their production lines without anytape splices which otherwise would become possible points of failure andwaste.

[0046] It should be further understood that manufacturing themono-axially oriented draw tape using the system 20 is generally lessexpensive and less complex than manufacturing draw tape using theconventional blown-film approach and the conventional multi-layerblown-film extrusion approach. In particular, the continuous nature ofthe system 20 and the method 100 provides an advantageous cost effectiveuse of resources (e.g., no winding and unwinding sheets). Furtherdetails of the invention will now be provided with reference to FIGS.8-10.

[0047]FIG. 8 shows a block diagram of a draw tape bag manufacturingsystem 110 which is suitable for use by the invention. The draw tape bagmanufacturing system 110 includes a source of mono-axially oriented drawtape 112, a thermoplastic panel source 114, a folding and positioningassembly 116, and a fastening assembly 118. The thermoplastic panelsource 114 provides sets of thermoplastic panels to the folding andpositioning assembly 116 (e.g., separate sets of thermoplastic panels, along feed of thermoplastic material that can later be cut into sets ofthermoplastic panels, partially cut sets of thermoplastic panels whichremain at least partially attached to each other in a series, etc.). Thesource of mono-axially oriented draw tape 112 provides mono-axiallyoriented draw tape strips to the folding and positioning assembly 116(e.g., separate draw tape strips, long feeds of draw tape that can laterbe cut into separate draw tape strips, partially cut draw tape stripswhich remain at least partially attached to each other in a series,etc.).

[0048] In one arrangement, the source of mono-axially oriented draw tape112 operates simultaneously with the other components 114, 116, 118 thusavoiding a need to wind and unwind the draw tape prior to its use indraw tape bags. The earlier-described mono-axially oriented draw tapemanufacturing system 20 (FIG. 1), e.g., without the winding assembly 40or with the winding assembly 40 so that the generated rolls 22 of drawtape can be transferred to another location for use in draw tape bags,is suitable for use as the source of single-layer mono-axially orienteddraw tape 112.

[0049]FIG. 9 shows a procedure 130 performed by the draw tape bagmanufacturing system 110. In step 132, the folding and positioningassembly 116 receives a set of mono-axially oriented draw tape stripsfrom the source of mono-axially oriented draw tape 112, and a set ofthermoplastic panels from the thermoplastic panel source 114. Thefolding and positioning assembly 116 then configures a set ofthermoplastic panels to define (i) a bag cavity and a (ii) set of hemchannels. Optionally, the folding and positioning assembly 116 canperform additional operations as this point such as cutting holes in thehem channels to enable a user to later access draw tape through theholes.

[0050] In step 134, the folding and positioning assembly 116 positionsthe set of mono-axially oriented draw tape strips relative to the set ofhem channels such that each mono-axially oriented draw tape strip isdisposed within a respective hem channel. In one arrangement, themono-axially oriented draw tape strips consist of single-layermono-axially oriented LLDPE.

[0051] In step 136, the fastening assembly 118 and then fastens eachmono-axially oriented draw tape strip to the set of thermoplasticpanels. In particular, the fastening assembly 118 heat seals pairs ofends of the draw tape strips to the set of thermoplastic panels formingthe bag cavity and a set of hem channels thus forming a draw tape bag(e.g., using a stamp/press process, using a rotating stamping process,etc.). The draw tape bag manufacturing system 110 can include additionalstages such as the winding stage which winds multiple draw tape bags(e.g., slightly attached along a perforated edge) onto a reel forsubsequent storage and/or shipping.

[0052]FIG. 10 is a perspective view of a draw tape bag 140 (e.g., atrash bag, a reusable plastic bag, a shopping bag, etc.) produced by thedraw tape bag manufacturing system 110. The draw tape bag 140 includes aset of thermoplastic panels 142 which are configured to define a bagcavity 144 and a set of hem channels 146 (e.g., tubular hems). Inparticular, a thermoplastic panel 142-A forms one side of the bag 140and a hem channel 146-A, and a thermoplastic panel 142-B forms anotherside of the bad 140 and a hem channel 146-B.

[0053] The draw tape bag 140 further includes a set of mono-axiallyoriented draw tape strips 148 which reside within the set of hemchannels 146. In particular, a mono-axially oriented draw tape strip148-A resides in the hem channel 146-A, and a mono-axially oriented drawtape strip 148-B resides in the hem channel 146-B.

[0054] Each thermoplastic panel 142 defines a hole 150 in the hemchannel 146 of that panel. In particular, the thermoplastic panel 142-Adefines a hole 150-A in the hem channel 146-A. Similarly, thethermoplastic panel 142- B defines a hole 150-B in the hem channel146-B. The holes 152 permit a user to access the draw tape strips 148 toclose the bag 140 and/or carry the bag 140.

[0055] It should be understood that the bag 140 includes a number ofheat seals 152 which hold particular parts of the bag 140 together. Inparticular, the bag 140 includes heat seals 152-1, 152-2 along the sidesof the thermoplastic panels 142-A, 142-B so that the panels 142-A, 142-Battach along three sides to form the bag cavity 144 (the thermoplasticpanels 142 being attached and folded over each other along one side 154of the three sides). Additionally, the bag 140 includes heat seals152-3, 152-4 to form the hem channels 146-A, 146-B.

[0056] It should be further understood that each draw tape strip 148-A,148-B is fastened to the set of thermoplastic panels 142-A, 142-B by aheat seal. In particular, one end of each draw tape strip 148-A, 148-Bis heat sealed to one edge of the bag 140 along the heat seal 152-1 at alocation 156-1, and another end of each draw tape strip 148-A, 148-B isheat sealed to another edge of the bag 140 along the heat seal 152-2 ata location 156-2.

[0057] In one arrangement, each draw tape strip 148-A, 148-B is asection of single-layer mono-axially oriented LLDPE. Since LLDPE has alower melting point than HDPE or a typical blend of HDPE andlower-density material, less heat and time is required to heat seal thedraw tape strips 148-A, 148-B. Accordingly, the cost of manufacturingdraw tape bags 140 using such draw tape strips 148-A, 148-B is lowerthan that for manufacturing draw tape bags using HDPE (e.g., aconventional multi-layer draw tape having an HDPE core, a conventionaldraw tape made from a 20/80 blend of LLDPE and HDPE, etc.).

[0058] As described above, embodiments of the invention are directed totechniques for making mono-axially oriented draw tape which is useful incertain applications such as in draw tape bags 140, the draw tape bags140 themselves, and related processes, products and components. Suchtechniques involve stretching and annealing a feed 54 of draw tape toorient molecules within the draw tape feed 54 such that the tensilestrength of the draw tape feed 54 is greater in a particular direction(e.g., a direction along the draw tape feed). Accordingly, amanufacturer can use certain materials (e.g., LLDPE) to fabricate a drawtape which requires less heat and time to fasten to thermoplastic panelsthan typical draw tapes (e.g., a single-layer draw tape consisting of ablend of 20% LLDPE and 80% HDPE, a multi-layer draw tape having an HDPEcore, etc.) when manufacturing the draw tape bag 140, but which stillprovides strength that is equal to or greater than a conventional drawtape in a particular direction (e.g., the direction along the draw tapefeed). Additionally, the process for making the draw tape can beperformed in a contiguous manner thus enabling production of essentiallyunlimited lengths of draw tape thus enabling the manufacture of drawtape bags 140 without any tape splices which otherwise would posepossible points of failure. The features of the invention, as describedabove, may be employed in draw tape manufacturing systems, devices,products and methods for making mono-axially oriented draw tape, as wellas various systems, products (e.g., draw tape bags) and methods whichuse such tape, such as those of Film X, Inc. of Dayville, Conn.

[0059] While this invention has been particularly shown and describedwith references to preferred embodiments thereof, it will be understoodby those skilled in the art that various changes in form and details maybe made therein without departing from the spirit and scope of theinvention as defined by the appended claims.

[0060] For example, it should be understood that various stages of themono-axially oriented draw tape manufacturing system 20 were provided byway of example only. One or more of the stages can be omitted, and oneor more other stages can be added. For instance, the cutting assembly 36is not required to make a mono-axially oriented film for draw tape, butis useful in some applications such as when winding long lengths of drawtape without splices. As another example, a step of color incorporationcan be performed by the front-end assembly 42 (e.g., during thedrying/mixing stage, see the drying/mixing assembly 28 of FIG. 1) inorder to provide the mono-axially oriented draw tape with a particularcolor (e.g., yellow, red, etc.). As yet another example, a step of slipagent incorporation can be performed by the front-end assembly 42 (e.g.,during the mixing stage) in order to provide the mono-axially orienteddraw tape with a particular coefficient of friction.

[0061] Additionally, it should be understood that the draw tapemanufacturing system 20 was described as providing draw tape consistingof single-layer LLDPE by way of example only. In other arrangements, thedraw tape can include other materials such as a percentage of HDPE forapplications requiring enhanced strength, LDPE, EVA, or otherthermoplastic polymers, , etc.

[0062] Furthermore, it should be understood that the draw tape made bythe manufacturing system 20 can undergo additional processes beyond theprocesses identified above. For example, the draw tape can be stamped orprinted with designs (e.g., trademarks, symbols, logos, etc.) or treated(e.g., sprayed or coated with a low friction agent) in intermediatestages (e.g., between the orientating assembly 38 and the windingassembly 40) or in subsequent stages (e.g., just prior to installationin hem channels when manufacturing a draw tape bag 140).

[0063] Additionally, it should be understood that the ratio of 2.8 to1.0 of lengths between the draw tape feeds 56 exiting the orientatingassembly 38 and the draw tape feeds 54 entering the orientating assembly38 was provided by way of example only. In other arrangements, the ratiois different (e.g., anywhere in a range of 1.05 to 1.0 through 10.0 to1.0).

[0064] Furthermore, it should be understood that the draw tape bagmanufacturing system 110 was described as including the source ofmono-axially oriented draw tape 112 by way of example only. In otherarrangements, the draw tape bag manufacturing system 110 includes otherdraw tape sources such as sources which utilized a blown-film approachor a multi-layer extrusion approach, but that operate in a contiguousmanner to provide essentially unlimited feeds of draw tape withoutwinding and unwinding the draw tape prior to its use in draw tape bags.

What is claimed is:
 1. A method for making mono-axially oriented drawtape, the method comprising the steps of: forming a solid sheet ofthermoplastic material from molten thermoplastic material; producing aset of draw tape feeds from the solid sheet of thermoplastic material;and stretching and annealing the set of draw tape feeds to orientmolecules within the set of draw tape feeds such that tensile strengthof each draw tape feed is greater in a first direction than in a seconddirection which is substantially perpendicular to the first direction.2. The method of claim 1 wherein the step of stretching and annealingincludes the step of: passing the set of draw tape feeds around a seriesof rotating temperature-controlled rollers to stretch and anneal the setof draw tape feeds, wherein the series of rotatingtemperature-controlled rollers includes a first roller which isconfigured to rotate at a first rate and have a first temperature, and asecond roller which is configured to rotate at a second rate that isdifferent than the first rate and have a second temperature that isdifferent than the first temperature.
 3. The method of claim 1 whereinthe step of producing the set of draw tape feeds includes the step of:cutting the solid sheet of thermoplastic material along the firstdirection to produce, as the set of draw tape feeds, separate feeds ofdraw tape.
 4. The method of claim 3, further comprising the step of:after the step of stretching and annealing, simultaneously winding theseparate feeds of draw tape onto respective hubs in order tosimultaneously form multiple rolls of draw tape.
 5. The method of claim1 wherein the molten thermoplastic material includes molten linearlow-density polyethylene, and wherein the step of forming the hardenedsheet of thermoplastic material includes the step of: cooling the moltenlinear low-density polyethylene in a bath in order to form, as the solidsheet of thermoplastic material, a single solid layer of linearlow-density polyethylene.
 6. The method of claim 5 wherein the step offorming the solid sheet of thermoplastic material further includes thestep of: prior to the step of cooling, extruding the molten linearlow-density polyethylene through a die that defines an elongatedopening.
 7. Mono-axially oriented draw tape made by a method comprisingthe steps of: forming a solid sheet of thermoplastic material frommolten thermoplastic material; producing a set of draw tape feeds fromthe solid sheet of thermoplastic material; and stretching and annealingthe set of draw tape feeds to orient molecules within the set of drawtape feeds such that tensile strength of each draw tape feed is greaterin a first direction than in a second direction which is substantiallyperpendicular to the first direction.
 8. The mono-axially oriented drawtape of claim 7 wherein the step of stretching and annealing includesthe step of: passing the set of draw tape feeds around a series ofrotating temperature-controlled rollers to stretch and anneal the set ofdraw tape feeds, wherein the series of rotating temperature-controlledrollers includes a first roller which is configured to rotate at a firstrate and have a first temperature, and a second roller which isconfigured to rotate at a second rate that is different than the firstrate and have a second temperature that is different than the firsttemperature.
 9. The mono-axially oriented draw tape of claim 7 whereinthe step of producing the set of draw tape feeds includes the step of:cutting the solid sheet of thermoplastic material along the firstdirection to produce, as the set of draw tape feeds, separate feeds ofdraw tape.
 10. The mono-axially oriented draw tape of claim 8 whereinthe method further comprises the step of: after the step of stretchingand annealing, simultaneously winding the separate feeds of draw tapeonto respective hubs in order to simultaneously form multiple rolls ofdraw tape.
 11. The mono-axially oriented draw tape of claim 7 whereinthe molten thermoplastic material includes molten linear low-densitypolyethylene, and wherein the step of forming the solid sheet ofthermoplastic material includes the step of: cooling the molten linearlow-density polyethylene in a bath in order to form, as the solid sheetof thermoplastic material, a single solid layer of linear low-densitypolyethylene.
 12. The mono-axially oriented draw tape of claim 11wherein the step of forming the solid sheet of thermoplastic materialfurther includes the step of: prior to the step of cooling, extrudingthe molten linear low-density polyethylene through a die that defines anelongated opening.
 13. A system for making mono-axially oriented drawtape, comprising: a front-end assembly that is configured to form asolid sheet of thermoplastic material from molten thermoplasticmaterial; an intermediate assembly, coupled to the front-end assembly,that is configured to produce a set of draw tape feeds from the solidsheet of thermoplastic material; and an orientating assembly, coupled tothe intermediate assembly, that is configured to stretch and anneal theset of draw tape feeds to orient molecules within the set of draw tapefeeds such that tensile strength of each draw tape feed is greater in afirst direction than in a second direction which is substantiallyperpendicular to the first direction.
 14. The system of claim 13 whereinthe orientating assembly includes a series of rotatingtemperature-controlled rollers which are configured to stretch andanneal the set of draw tape feeds, wherein the series of rotatingtemperature-controlled rollers includes a first roller which isconfigured to rotate at a first rate and have a first temperature, and asecond roller which is configured to rotate at a second rate that isdifferent than the first rate and have a second temperature that isdifferent than the first temperature.
 15. The system of claim 13 whereinintermediate assembly includes: a cutting assembly that is configured tocut the solid sheet of thermoplastic material along the first directionto produce, as the set of draw tape feeds, separate feeds of draw tape.16. The system of claim 14, further comprising: a winding assembly,coupled to the orientating assembly, that is configured tosimultaneously wind the separate feeds of draw tape onto respective hubsin order to simultaneously form multiple rolls of draw tape.
 17. Thesystem of claim 13 wherein the molten thermoplastic material includes:molten linear low-density polyethylene, and wherein the front-endassembly includes: a bath assembly that is configured to cool the moltenlinear low-density polyethylene in order to form, as the solid sheet ofthermoplastic material, a single solid layer of linear low-densitypolyethylene.
 18. The system of claim 16 wherein the front-end assemblyfurther includes: a extruder coupled to the bath assembly, wherein theextruder includes a die that defines an elongated opening, and whereinthe extruder is configured to extrude the molten linear low-densitypolyethylene through the die.
 19. A method for making a draw tape bag,the method comprising the steps of: configuring a set of thermoplasticpanels to define (i) a bag cavity and (ii) a set of hem channels;positioning a set of mono-axially oriented draw tape strips relative tothe set of hem channels such that each mono-axially oriented draw tapestrip is disposed within a respective hem channel; and fastening eachmono-axially oriented draw tape strip to the set of thermoplasticpanels.
 20. The method of claim 19 wherein each draw tape strip is asection of single-layer mono-axially oriented linear low-densitypolyethylene having a pair of ends, and wherein the step of fasteningincludes the step of: heat sealing the pair of ends of each strip ofsingle-layer mono-axially oriented linear low-density polyethylene tothe set of thermoplastic panels.
 21. A draw tape bag, comprising: a setof thermoplastic panels which is configured to define (i) a bag cavityand (ii) a set of hem channels; and a set of mono-axially oriented drawtape strips, wherein each mono-axially oriented draw tape strip isdisposed within a respective hem channel, and wherein each mono-axiallyoriented draw tape strip fastens to the set of thermoplastic panels. 22.The draw tape bag of claim 21 wherein each draw tape strip is a sectionof single-layer mono-axially oriented linear low-density polyethylenehaving a pair of ends which is heat sealed to the set of thermoplasticpanels.
 23. A system for making a draw tape bag, comprising: a foldingand positioning assembly that (i) configures a set of thermoplasticpanels to define a bag cavity and a set of hem channels, and (ii)positions a set of mono-axially oriented draw tape strips relative tothe set of hem channels such that each mono-axially oriented draw tapestrip is disposed within a respective hem channel; and a fasteningassembly, coupled to the folding and positioning assembly, that fastenseach mono-axially oriented draw tape strip to the set of thermoplasticpanels.
 24. The system of claim 23 wherein each draw tape strip is asection of single-layer mono-axially oriented linear low-densitypolyethylene having a pair of ends, and wherein the fastening assemblyis configured to heat seal the pair of ends of each section ofsingle-layer mono-axially oriented linear low-density polyethylene tothe set of thermoplastic panels.